Grease composition containing a powdery molybdenum oxysulfide dithiocarbamate composition

Abstract: A grease composition is described comprising 0.1 to 10 parts by weight of a powdery molybdenum oxysulfide dithiocarbamate composition which comprises a compound represented by the following general formula (1): wherein R 1 , R 2 , R 3 and R 4 are independent hydrocarbyl groups and may be the same or different groups, and the total number of carbon atoms contained in R 1 to R 4 is 4 to 36; and wherein X is sulfur or oxygen and the composition of the total of all Xs is given as S m O n in which n and m satisfy the ranges of 1.7 ≤ m ≤ 3.5 and 0.5 ≤ n ≤ 2.3, respectively, and in which the constituent particles have diameters of not larger than 50 µm, based on 100 parts by weight of a base grease.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a grease composition containing powdery molybdenum oxysulfide dithiocarbamate composition. 2. Description of the Related Art Heretofore, adding molybdenum oxysulfide dithiocarbamate to grease has been tried in order to improve extreme pressure properties. friction modifier properties and anti-wear properties of grease. Various methods for producing such molybdenum oxysulfide dithiocarbamate have been disclosed. For example, US-A-3 356 702 discloses a method by which a compound having the general formula: [R 2 N-CS-S] 2 Mo 2 O m S n (wherein m + n = 4, m = 2.35-3, n = 1.65-1, and R is a hydrocarbyl group having 1 to 24 carbon atoms) can be produced by reacting together a secondary amine, carbon disulfide and molybdenum trioxide. Japanese Patent Laid-Open No.48-56202 discloses a method in which a compound represented by the following general formula: (wherein R is an alkyl group) can be produced by reacting the product given by the method of Japanese Patent Publication No.45-24562 described above with phosphorus pentasulfide, In addition, GB-A-1 556 428 discloses methods by which a compound represented by the following general formula: (wherein R 5 and R 6 are independently hydrocarbyl groups having 1 to 24 carbon atoms, l is a number from 0.5 to 2.3, o is a number from 3.5 to 1.7 and l + o = 4) can be produced by reacting carbon disulfide with a secondary amine in an aqueous solution or suspension containing molybdenum trioxide or an alkali metal salt or an ammonium salt of molybdic acid and an alkali hydrogensulfide or an alkali sulfide in a molar ratio of 1 : 0.05-4. However, the compound of Japanese Patent Publication No. 45-24562 above is inferior in heat resistance and, in the grease preparation process, may cause a color change in the resulting grease. On the other hand, the compound described in Japanese Patent Laid-Open No. 48-56202 exhibits corrosive action against copper plates, thus the use of the compound has been limited. The compound described in GB-A-1 556 428 also still has room for improvement in terms of lubricating properties and corrosive properties. That is, when the powdery molybdenum oxysulfide dithiocarbamate is added to the grease to prepare a grease composition, its physical properties such as particle size have been neglected. As a result, the grease composition produced is not imparted with sufficient lubricating properties, and furthermore may cause slight vibrations. GB-A-1087630 discloses molybdenum (VI) dialkyldithiocarbamates as lubricant additives. Particularly preferred in GB-A-1087630 are molybdenum (VI) di-n-propyldithiocarbamates having the formula Mo VI O 2 [(n-C 3 H 7 ) 2 NCS 2 ] 2 , molybdenum (VI) diamyldithio-carbamates having the formula Mo VI O 2 [(n-C 5 H 11 ) 2 NCS 2 ] 2 and molybdenum (VI) di-2-ethylhexyldithio-carbamates having the formula Mo VI O 2 [(n-C 8 H 17 ) 2 NCS 2 ] 2 and the H 2 S reaction products of these compounds. The object of the present invention is to provide a grease composition which exhibits excellent wear and friction properties and, therefore, exhibits excellent lubricity properties, as well as less corrosive action. DETAILED DESCRIPTION OF THE INVENTION The present inventors have carried out extensive research on various kinds of purified molybdenum oxysulfide dithiocarbamate from the viewpoint of corrosive action and lubricating properties. As a result, they have found a component effective for use as an additive for a grease composition and a process for producing the component, thereby attaining the present invention. That is, according to the present invention, a powdery molybdenum oxysulfide dithiocarbamate composition can be provided which comprises a compound represented by the following general formula (1): (wherein R 1 , R 2 , R 3 and R 4 are independent hydrocarbyl groups and may be the same or different groups, and the total number of carbon atoms contained in R 1 to R 4 is 4 to 36; and wherein X is sulfur or oxygen and the composition of the total of all Xs is given as S m O n in which m and n satisfy the ranges of 1.7 ≦ m ≦ 3.5 and 0.5 ≦ n ≦ 2.3, respectively), and in which constituent particles have diameters of not larger than 50µm, with the proviso that the powdery molybdenum oxysulfide dithiocarbamate composition is not prepared according to the process as follows: (A) an aqueous solution or suspension prepared by reacting (a) molybdenum trioxide or an alkali metal salt or ammonium salt of molybdic acid with (b) alkali hydrogensulfide or alkali sulfide in a molar ratio of (a):(b) = 1:1 to 1:2, (B) carbon disulfide, (C) secondary amine and (D) mineral acid are reacted together, wherein the molar ratio of (A), (B) and (C) is (A):(B):(C) = 1 : 0.9-2 : 0.9-2 and the amount of (D) to be added is within the range satisfying the following equation (1): 1- [(R'/4) + 1] × 1/10≦d≦1 [wherein R' is the total number of carbon atoms contained in R 1 , R 2 , R 3 and R 4 in formula (1) and d is the equivalent number of the alkali in the mineral acid as opposed to the alkali present in (A)] when the alkali equivalent in (A) is defined as 1, whereby a solid reaction product is obtained; the resulting reaction product is slurried with an organic solvent; and then the resulting slurry is washed, dried and powdered. The grease composition of the present invention is characterized by containing 0.1 to 10 parts by weight of a powdery molybdenum oxysulfide dithiocarbamate composition which comprises a compound represented by the following general formula (1): (wherein R 1 , R 2 , R 3 , R 4 , X, m and n are the same as defined above), and of in which constituent particles have diameters of not larger than 50µm, based on 100 parts by weight of a base grease. In the compound of formula (1) to be used in the present invention, the hydrocarbyl groups represented by R 1 , R 2 , R 3 and R 4 may be saturated or contain unsaturated bond(s), may be straight chains. branched chains or cyclic chains or any combined form thereof, and may be the same or different. However, the total number of carbon atoms contained in R 1 , R 2 , R 3 and R 4 should be 4 to 36, preferably 4 to 32. and more preferably 8 to 32. When the total number is greater than the range above, the compound exhibits a lower melting point and therefore may become viscous at ordinary temperatures, resulting in poor handling. which is not desirable. As such hydrocarbyl groups, aliphatic, aromatic and aromatic-aliphatic groups can be employed. Typical examples of such hydrocarbyl groups include alkyl groups such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, hexyl, octyl. 2-ethylhexyl, nonyl, decyl, lauryl. tridecyl, isotridecyl, myristyl; palmityl and stearyl; alkenyl groups such as propenyl, butenyl, isobutenyl, pentenyl, 2-ethylhexenyl. octenyl, oleyl and palmitoleyl; cycloalkyl groups such as cyclopentyl. cyclohexyl, methylcyclohexyl and ethylcyclopentyl; aryl groups such as phenyl, naphthyl and alkyl substituent phenyl; aralkyl groups such as benzyl and phenethyl; and so on. Among these, preferably used are ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, hexyl, heptyl, octyl, 2-ethylhexyl and the like. In the compound of formula (1), X is sulfur or oxygen, and the composition of the total of all Xs is given as S m O n wherein m satisfies the range of 1.7 ≦ m ≦ 3.5 and preferably 1.8 ≦ m ≦ 3.0 and n satisfies the range of 0.5 ≦ n ≦ 2.3 and preferably 1.0 ≦ n ≦ 2.2. When n is higher than the above range (i.e. n is lower than the above range), the compound exhibits undesirable corrosive properties. On the other hand, when m is lower than the above range (i.e n is higher than the range above), the compound exhibits poor lubricating properties. For these reasons, values of m and n which lie outside of the above range are not preferable. In the molybdenum oxysulfide dithiocarbamate composition of the present invention which comprises a compound represented by formula (1), the constituent particles, i.e. the molybdenum oxysulfide dithiocarbamate particles, have diameters of not larger than 50µm. Preferably, the composition contains particles of molybdenum oxysulfide dithiocarbamate of not smaller than 40 to not larger than 50µm in diameter in an amount of not more than 5% by weight and particles of smaller than 40µm in diameter in an amount of not less than 95% by weight, based on the total weight of the particles. Furthermore, in the molybdenum oxysulfide dithiocarbamate composition, it is most preferable that the average diameter of all of the particles is not larger than 20µm in addition to the conditions described above. An increase in particle diameter of the powdery molybdenum oxysulfide dithiocarbamate may cause not only a decrease in dispersibility in grease but also less effective lubricating properties thereof. For these reasons, the molybdenum oxysulfide dithiocarbamate particles which compose the powdery molybdenum oxysulfide dithiocarbamate composition of the present invention should have particle diameters of not larger than 50µm. Such powdery molybdenum oxysulfide dithiocarbamate compositions may be produced by synthesizing a molybdenum oxysulfide dithiocarbamate composition according to a conventional process known and then sieving the resultant composition. The grease composition of the present invention can be obtained by using the powdery molybdenum oxysulfide dithiocarbamate composition, wherein the composition is added to a base grease in an amount of 0.1 to 10 parts by weight, preferably 0.5 to 5 parts by weight, based on 100 parts by weight of the base grease. The grease composition thus obtained exhibits less corrosive action and has excellent lubricating properties. If the content of the molybdenum oxysulfide dithiocarbamate composition is less than the above described range, sufficient lubricating properties can not be imparted. On the other hand, even if the content of the composition is higher than the above range, the intended effects can not be further improved. For these reasons, too low or too high a content of the composition is not appropriate industrially. The base grease to be used in the grease composition is, for example, a metallic soap grease, a metallic soap complex grease, an urea-based grease or a grease using organically treated clay (e.g. bentone grease), in which a mineral oil and/or a synthetic oil is used. The grease composition of the present invention may be incorporated with an extreme pressure agent such as zinc dithiophosphate, a sulfur-phosphorous compound or molybdenum dithiophosphate, etc. and a solid lubricant such as molybdenum disulfide, graphite and ethylene tetrafluoride etc.. In addition, if necessary, other conventional components may also be added to the grease composition as additives for grease, such as a rust preventative (e.g. N-N-trimethylenediaminedioleate, sorbitan monooleate, etc.), an antioxidant (e.g. dioctyl phenylamine, butyl hydroxytoluene, etc.), etc. in an amount within the range conventionaly employed. EXAMPLES The present invention will be illustrated in more detail by the following examples. However, it is to be understood that the invention is not intended to be limited by the examples. In the Examples and Comparative Examples, the samples synthesized in the following Synthesis Examples were used. Synthesis Example 1 Into a glass reactor, 500ml of water and 144g (1 mole) of powdered molybdenum trioxide were suspended, and then 221g (1.5 moles) of 38 wt%-aqueous sodium hydrogensulfide solution was added to the resulting suspension while stirring under closed conditions, followed by reaction for about 30 min. Subsequently, 260g of toluene was added to the reaction mixture, and 146g (1.2 moles) of 30 wt%-aqueous hydrochloric acid solution was further added thereto. After further adding 142g (1.1 moles) of di-n-butylamine and 84g (1.1 moles) of carbon disulfide at room temperature, the resulting mixture was stirred at room temperature for 30 minutes and then heated to 95 to 102°C to be reacted for 4 hours. The resulting reaction product was filtered without slurrying, washed initially with 300ml of toluene and then with 300ml of water and dried, thereby obtaining 662g (95% yield) of a solid reaction product of a compound having the following formula: wherein the composition of all Xs was S 2 O 2 . Subsequently, the solid thus obtained was finely powdered for 2 hours using a mill, whereby a yellow powder (Sample 1) was obtained. Sample 1 was fractionated by sieving. As a result, a powder composed of particles having diameters of not smaller than 50µm (Sample 2), a powder composed of particles having diameters of not smaller than 40µm and smaller than 50µm (Sample 3) and a powder composed of particles having diameters of smaller than 40µm (Sample 4) were obtained. Synthesis Example 2 Into a glass reactor, 300ml of water and 144g (1 mole) of powdered molybdenum trioxide were suspended, and then 221g (1.5 moles) of 38 wt%-aqueous sodium hydrogensulfide solution was added to the resulting suspension while stirring under closed conditions followed by reaction for about 30 min. Subsequently. 260g of methanol was added to the reaction mixture, and 91g (0.75 mole) of 30 wt%-aqueous hydrochloric acid solution was further added thereto. After further adding 265g (1.1 moles) of di-2-ethylhexylamine and 84g (1.1 moles) of carbon disulfide at room temperature, the resulting mixture was stirred at room temperature for 30 minutes and then heated to 95 to 102°C to be reacted for 4 hours. The reaction product was present in a methanol-water emulsion as aggigations. The reaction product was filtered without slurrying, washed initially with 300ml of methanol and then with 300ml of water and dried, thereby obtaining 648g (95% yield) of a solid reaction product. Subsequently. the solid thus obtained was finely powdered for 2 hours using a mill, whereby a yellow powder (Sample 5) was obtained. Sodium content and particle diameters of Samples 1 to 5 given by Synthesis Examples 1 and 2 are summarized in Table 1. In this evaluation of each sample, the sodium content was determined according to the ICP method after ashing the sample, and the particle diameter was determined by laser diffusion using a microtrack particle size distribution analyzer after dispersing the sample in methanol. Sample No. 1 2 3 4 5 Sodium content (ppm) 650 850 800 560 500 Particle size distribution (%) not smaller than 50µm 18 100 16 40 - 50µm 14 100 13 smaller than 40µm 68 100 71 Average particle diameter(µm) 28.5 66.2 44.0 14.1 26.2 Example 1 and Comparative Example 1 Samples 6 to 9 were prepared by using Samples 2 to 4 above in the blending ratio shown in Table 2. Samples 1 to 5 and Samples 6 to 9 thus prepared were tested for dispersibility in grease and the lubrication. The results are summarized in Table 3. Sample No. 6 7 8 9 Blending ratio Sample 2 5% 5% Sample 3 5% 10% 10% Sample 4 95% 85% 95% 90% Average particle diameter (µm) 15.6 19.7 16.7 17.1 Example 1 Comparative Example Sample No. 3 4 6 9 1 2 5 7 8 Dispersibility in grease test Number of aggregates 29 12 19 25 39 51 32 50 42 SRV friction test Friction coefficient (after 30 min.) 0.098 0.085 0.092 0.095 0.105 0.105 0.104 0.105 0.104 Amplitude of friction coefficient (after 30 min.) 0.018 0.010 0.015 0.018 0.025 0.025 0.021 0.022 0.023 Dispersibility in grease test Into a kneader, 100 parts by weight of a urea grease and 3 parts by weight of each sample were charged, and then mixed at 80°C for 2 hours. Thereafter, the resulting grease mixture was applied on a glass plate in a thickness of about 1 mm, and then the dispersing state of the sample in the grease mixture was observed by means of a 20× reflection microscope. The dispersibility in grease of each sample was evaluated by counting the number of aggregations of the sample which were present within the 3 mm 2 on the plate. Friction test The friction test was carried out by means of a SRV dynamic friction test machine under the following conditions. The friction properties of each sample were evaluated by reading the coefficient of friction given after 30 minutes and the deflection of the coefficient of friction caused by a slight vibration. In this test, the same grease mixtures were used as those used in the dispersion test above. Test conditions: Load: 50 N Temperature: 50°C Test time: 60 min. Amplitude: 1 mm Frequency of amplitude: 50 times/sec. The effect of the present invention is that a grease composition which exhibits excellent wear and abrasive properties and, therefore, exhibits excellent lubricating properties, as well as decreased corrosive action can be provided. That is, the grease composition of the present invention, which comprises a molybdenum oxysulfide dithiocarbamate composition having ready dispersibility in a base grease, can exhibit excellent friction and abrasive properties and decreased corrosive action in a lubrication system, and therefore, can be used as a grease for all purposes such as in synchronized joints of automobiles.

Claims: A grease composition comprising 0.1 to 10 parts by weight of a powdery molybdenum oxysulfide dithiocarbamate composition which comprises a compound represented by the following general formula (I) : wherein R 1 , R 2 , R 3 and R 4 are independent hydrocarbyl groups and may be the same or different groups, and the total number of carbon atoms contained in R 1 to R 4 is 4 to 36; and wherein X is sulfur or oxygen and the composition of the total of all Xs is given as S m O n in which m and n satisfy the ranges of 1.7 ≤ m ≤ 3.5 and 0.5 ≤ n ≤ 2.3, respectively, and in which the constituent particles have diameters of not larger than 50 µm, based on 100 parts by weight of a base grease with the proviso that the powdery molybdenum oxysulfide dithiocarbamate composition is not prepared according to the process as follows: (A) an aqueous solution or suspension prepared by reacting (a) molybdenum trioxide or an alkali metal salt or an ammonium salt of molybdic acid with (b) alkali hydrogensulfide or alkali sulfide in a molar ratio of (a):(b) = 1:1 to 1:2, (B) carbon disulfide, (C) secondary amine, and (D) mineral acid are reacted together, wherein the molar ratio of (A), (B) and (C) is (A):(B):(C) = 1 : 0.9-2 : 0.9-2 and the amount of (D) to be added is within the range satisfying the following equation (1): 1 - [(R'/4) + 1] × 1/10≦d≦1 [wherein R' is the total number of carbon atoms contained in R 1 , R 2 , R 3 and R 4 in the formula (1)] and d is the equivalent number of the mineral acid against the alkali present in (A)] when the alkali equivalent in (A) is defined as 1, whereby a solid reaction product is given; the resulting reaction product is slurried with an organic solvent; and then the resulting slurry is washed, dried and powdered. The grease composition according to claim 1 wherein the base grease is one selected from the group consisting of metallic soap greases, metallic soap complex greases, urea greases and greases using organically treated clay in which a mineral oil and/or a synthetic oil are used. The grease composition according to claim 1 or 2 which further comprises an extreme pressure agent, a solid lubricant, a rust preventative and/or an antioxidant. The grease composition according to claim 1 wherein the constituent particles of the powdery molybdenum oxysulfide dithiocarbamate composition are composed of not more than 5 percent by weight of particles having diameters of 40 to 50 µm and of not less than 95 percent by weight of particles having diameters smaller than 40 µm based on the total weight of the composition. The grease according to claim 1 wherein the constituent particles have an average diameter of not larger than 20 µm.

Inventors: FUKUSHIMA ARITOSHI, KAMKURA TAMIJI, MORITA KAZUHISA, TANAKA NORIYOSHI, TATSUMI YUKIO, FUKUSHIMA, ARITOSHI, KAMKURA, TAMIJI, MORITA, KAZUHISA, TANAKA, NORIYOSHI, TATSUMI, YUKIO, Fukushima, Aritoshi, c/oAsahi Denka Kogyo K.K.2-35, Kamkura, Tamiji, c/o Asahi Denka Kogyo K.K. 2-35, Morita, Kazuhisa, c/o Asahi Denka Kogyo K.K. 2-35, Tanaka, Noriyoshi, c/o Asahi Denka Kogyo K.K. 2-35, Tatsumi, Yukio, c/o Asahi Denka Kogyo K.K. 2-35
Applicants: ASAHI DENKA KOGYO KK, ASAHI DENKA KOGYO KABUSHIKI KAISHA
Application year: 1994
Main classification: C10M135
IPC codes: C10M135